Manchester-based Concept Metal Products Ltd, established in 1975, is a sheet metal work and fabrication specialist which offers shearing, bending, punching and laser cutting services. While the Concept Metal team was well-versed in CAD, it had virtually no experience with additive manufacturing (AM) but recognised that to speed up its processes, win more orders, and offer quicker turnround times, the 3-D printing of special tools was necessary.

One such tool, the 24 Vee metal shaper, a press brake tool, is used to form steel and aluminium sheets of varying sizes and thicknesses into various angles, channels, and similar pressed sections. Used in Concept Metal’s presses, the 24 Vee metal shaper is designed to withstand up to 40 tons per metre of pressure. This specialist tooling plays an essential role in shaping metal into custom V-shaped angles required by Concept Metal’s customers. Previously, the Concept Metal team had outsourced the production of the tool, which was machined from steel.

Alex Ritchie, Concept Metal administrator, said: “3-D printing is not commonplace in the sheet metal industry, but we were eager to learn how it could help support our business. A thorough training and education programme provided by Markforged University (MFU) made it easy for us to adapt and ultimately led to our decision to invest in our first Mark Two 3-D printer from Markforged. Thanks to MFU, we were able to reduce the AM learning curve and within just 24hr of setting up our new 3-D printer, we were producing our first tool.”

After purchasing the 3-D printer, Concept Metal now uses Onyx for its tooling production. This material, a flagship micro carbon-filled nylon from Markforged, is known for its high strength and toughness. Following the success of its first test print, Concept Metal has produced three more Vee metal shaper tools in different sizes.

Mr Ritchie continued: “Thanks to Markforged, we have achieved close to 75% cost savings by 3-D printing our own 24 Vee metal shapers in Onyx, rather than purchasing them in machined steel. Also, by bringing production of the tools in-house, we have been able to save time, reduce administration and lead times associated with outsourcing, from days down to just 17hr.”

He concluded: “In addition to saving time and costs on our own tooling, Markforged is opening up new business opportunities and revenue streams for us. We aim to expand the business to offer 3-D printed parts as a service, printing prototypes and components for both existing and new customers.”